Tool holding system having captive and non-releasable members, method of manufacture and assembly of same and cutting tool

A method of manufacture and assembly of a tool holding system (22, 122) having a tool holding system central axis (A) defining opposite forward and rear directions (DF, DR), the method comprising:

• manufacturing a mounting portion (26);
• manufacturing, by using an additive manufacturing process, a clamping head part (80, 180) comprising:
• inner and outer coupling members (36, 136;
• 38, 138) connected to one another;
• at least one connecting portion (92) connecting the inner and outer coupling members (36, 136;
• 38, 138);
• an annular separation cavity (94) bounded by the inner and outer coupling members (36, 136;
• 38, 138) and the at least one connecting portion (92);
• and
• a clamping head bore (88) opening out to at least the clamping head forward end surface (82) of the clamping head part (80, 180);
• separating the clamping head part (80, 180) into:
• an integrally formed one-piece inner coupling member (36, 136) forming at least part of a clamping sleeve portion (30) and having a clamping bore (32) opening out at a forward end (34) of the tool holding system (22, 122), the inner coupling member (36, 136) having a radially outwardly facing a first engagement surface (56);
• and
• an integral formed one-piece outer coupling member (38, 138) circumferentially disposed about at least a portion of the inner coupling member (36,36), the outer coupling member (38, 138) having a radially inwardly facing second engagement surface (58) which faces the first engagement surface (56);
• wherein:
• the inner and outer coupling members (36, 136;
• 38, 138) are permanently connected to one another, and are captively and non-releasably engaged with each other via the first and second engagement surfaces (56, 58);
• and
• connecting the clamping head part (80, 180) to the mounting portion (26).

A tool holding system (22, 122), having a tool holding system central axis (A) defining opposite forward and rear directions (DF, DR), the tool holding system (22, 122) comprising:

• a clamping portion (28) comprising:
• an integrally formed one-piece inner coupling member (36, 136) forming at least part of a clamping sleeve portion (30) having a clamping bore (32), for clampingly receiving a cutting insert (24), the clamping bore (32) opening out at a forward end (34) of the tool holding system (22, 122), the inner coupling member (36, 136) having a radially outwardly facing a first engagement surface (56);
• and
• an integrally formed one-piece outer coupling member (38, 138) having a radially inwardly facing second engagement surface (58);
• and
• a mounting portion (26) connected to one of the inner and outer coupling members (36, 136;
• 38, 138);
• wherein
• the outer coupling member (38;
• 138) is circumferentially disposed about at least a portion of the inner coupling member (36;
• 136), with the first engagement surface (56) facing the second engagement surface (58);
• the inner and outer coupling members (36, 136;
• 38, 138) are permanently connected to one another, and are captively and non-releasably engaged with each other, without the use of a separate retaining element keeping the two together;
• and
• the first and second engagement surfaces (56, 58) are slidingly displaceable with respect to each other to adjust the inner and outer coupling members between locked and released positions.